Tile wall



Nov. 18, 1958 H. A. TOULMIN, JR 2,860,505

TILE WALL Filed Dec. 11, 1953 INVENTOR. A. 702242172172 J2- I E I Har BY ATZ'UHNEYS T 2 m? v 96% d .zwv

TILE WALL Harry A. Toulmin, J12, Dayton, Ohio, assignor to The Commonwealth Engineering Company of @hio, Dayton, Ohio, a corporation of Ohio Application December 11, 1953, Serial No. 397,620

4 Claims. (Cl. 72-21) The present invention relates to a wall structure, more particularly to a light-weight ceramic tile wall structure having a fibrous glass filler.

In the past, ceramic tile has had only a limited application in the building construction field. This has been due largely to the weight of ceramic tile. In addition, the fragile nature of ceramic tile resulted in considerable difficulty and expense in erecting tile structures. Ceramic tile wall structures in particular are not extensively used primarily because of these characteristics of ceramic tiles. Furthermore, particularly in connection with ceramic tile wall structures diificulties arose in securing these wall structures to the overall structure in which the tile wall was being installed. While a permanent grouting is used in most all tile wall structures, this method is not completely satisfactory because the brittle nature of the ceramic tile results in fracture of the tile both in erection and in use.

A considerable percentage of the total weight of a ceramic tile wall structure resulted from the use of concrete or similar materials as supports. Moreover, the thick mass of the tile itself especially when used as a wash tile contributed to the total weight of the structure. Consequently, while it may have been desirable to use ceramic tile wall structures in various locations, the inherent characteristics of ceramic tiles, as discussed above, have deterred their extensive use.

This invention essentially comprises a fibrous glass mat which has a layer of ceramic tile on at least one side thereof. Means are provided on' the inner surfaces of these tile layers to interlockingly engage the fibrous glass mat. In addition, securing means are provided within the tile wall structure to engage the building surfaces in order to position the tile wall structure securely in place.

As fibrous glass, when reinforced with a suitable resin, is extremely light in Wight in contrast to concrete, it can be seen that the tile wall structure of this invention will be light in weight. Furthermore, as fibrous glass has good heat-insulating and shock-absorbing qualities, the tile wall structure of this invention will serve 'as an insulating structure.

This invention further provides means whereby a lightweight tile wall structure may be quickly positioned. These means comprise a slot to engage a key which is affixed to the floor upon which the tile wall structure is to rest, and also securing means located within the tile wall structure to fasten the tile wall structure to the wall surface of the building. in view of these advantages of this invention, it can be seen that a tile wall structure is provided which should render itself extremely desirable as a construction element.

It is, therefore, the primary objective of this invention to provide an improved tile wall structure.

It is another object of this invention to provide a lightweight tile wall structure which may be quickly and easily installed.

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It is a further object of this invention to provide a tile wall structure which has a fibrous glass filler.

It is an additional object of this invention to provide a. tile wall structure wherein the outer ceramic tile layers are interlocked with the fibrous glass filler.

It is still a further object of this invention to provide a light-weight tile wall structure having a fibrous glass filler and means to securely position the tile wall structure in respect to the co-operating wa'll surfaces.

Other objects and advantages of this invention will become readily apparent when taken in conjunction with the following description and the accompanying drawings, wherein:

Figure 1 is a perspective view of a room wherein there is installed a tile wall structure constructed in accordance with this invention;

Figure 2 is a partial sectional view taken along the line 22 in Figure 1, and shows the manner in which the tile facing is applied to .top of the wall structure, and also the means on the tile layers which interlockingly engage the fibrous glass filler;

Figure 3 is a partial sectional view taken along the line 33 in Figure 1, showing the manner in which the bottom of the tile wall structure of this invention engages a key secured to the floor surface, and also showing a cove base on the bottom of the tile wall structure; and

Figure 4 is a cutaway view of a portion of the tile wall structure of this invention showing the manner in which this tile wall structure may be secured to a stud member which forms a part of the building Wall surface.

Returning to the drawings, more particularly to Figure 1, wherein like reference characters indicate the same parts throughout the various views, 10 indiates generally a tile wall structure constructed in accordance with this invention. The tile wall structure 10 is illustrated as being installed in a room indicated generally as 11, which has a wall 12, and a floor 13. The tile wall structure 10 comprises a fibrous glass filler 14. The filler 14 is comprised of a mat of glass fibers which is impregnated with a suitable resin. The resin conventionally used is of the polyester type. As the mat 14 has as its primary purpose to act as a filler for the tile wall structure 10, it is not necessary that the mat 14 have any great strength properties, therefore in constructing this mat a high percentage by volume of glass fibers to polyester resin may be used. Such a high volume would be considered to be of the order of 60% or more.

Tile layers 15 and 16 are bonded to each face of the fi'brous mat 14. It is preferable that this bonding operation be carried out at the factory when the tile wall structure is being made. In this manner the fibrous glass mat may be built up upon one tile layer 15 and when a suitable thickness has been reached the other tile layer 16 may then be bonded to the fibrous glass mat 14. It is pointed out, however, that tile layers 15 and 16 may comprise a plurality of tile blocks which may be applied to the fibrous glass mat 14 on the job. The manner of construction in which individual tile blocks are used is illustrated in Figure 2 The tile layers 15 and 16 are bonded to the fibrous glass filler 14 by means of a suitable bonding agent indicated at 29 in Figure 2. Bonding agent 29 is preferably a mastic or any suitable cement. The characteristics of the bonding agent to be employed, and the exact manner in which the bonding agent is to be applied will vary considerably, depending upon whether the wall structure is constructed at the factory or is assembled on the job.

The tile facing 17 is secured to the top edge of the fibrous glass mat 14. A second tile facing is secured to the exposed vertical edge of the fibrous glass mat 14. In Figure 1 the tile facings 17 and 18 are shown as Patented Nov. 18, 1958" being one-piece members. However, if desired, facings 17- and 18 may comprise a plurality of tileblocks. The tile facings 17 and 18 are preferably applied on the job, but may be applied at the factory.

Locatedin the bottom edge 19 or" thefibrous glass mat 14 is a longitudinal groove 20 The groove 20 receives a closely fitting key 21, which isfastened to the floor 131 Proceeding forthe moment to Figure 4, there is disclosed therein securing means indicated generally as 22, for-fastening the tile wall structure to the wall 12. The wall 12 comprises a plurality of wooden studs one of which is indicated at 23 in Figure 4. The securing means 22- essentially comprises a metal insert 24' shaped substantially as shown in Figure 4, and has therein an aperture 25 (not shown). A suitably sized screw 26 is inserted through the opening 25 so as to threadedly engage the stud 23. As the metal insert 24 is rigidly embedded in fibrous glass filler 14, itcan be seen that the engagement of the screw 26 with the stud 23 will securely fasten the tile wall structure to the wall 12.

Returning to Figure 2, there is illustrated therein the means by which the tile layers and 16 interlockingly engage fibrous glass filler 14. This means consists of a plurality of spaced lugs 27 which project from the inner surfaces of the tile layers 15 and 16. The lugs 27 may have any suitable configuration, and may be spaced as desired from the inner surface of the tile layers 15 and 16. It is desirable, however, that the lugs 27 be as long as practicably possible in order to present as great a contact area as is feasible to the fibrous glass filler 14.

Progressing now to Figure 3, there is illustrated therein in somewhat greater detail the slot and key 21 arrangement which has previously been described in connection with Figure 1. In addition, Figure 3 discloses the use of cove base members 28 in place of substantially flat base members as illustrated in the wall structure disclosed in Figure 1. Figure 3 also discloses a somewhat different arrangement of the interlocking lugs 27. The exact arrangement of interlocking lugs 27 to be used would depend to a great extent upon the size of the tile wall structure to be installed.

The tile wall structure disclosed in this invention has considerably more uses than that illustrated in Figure 1. In Figure 1 the tile Wall structure 10 is shown as being used as a partition in a lavatory. It should be borne in mind, however, that this tile wall structure may easily be used as a floor-to-ceiling partition. In this situation it might be desirable to use the cove members 28, illustrated in Figure 3, both at the top and at the bottom of the tile wall structure. Nor is the use of this, invention limited to lavatories. It would be desirable to employ this structure in laboratories, hospitals, and. the like. In fact, this invention may be satisfactorily utilized in virtually any building construction where the use of tile is desired for any reason.

It will be understood that this invention is susceptible to modification in order to adapt it. to different usages and conditions, and, accordingly, it is desired. to comprehend such modifications within this invention as may fall within the scope of the appended claims.

What is claimed as this invention is:

1. A wall structure comprising a fibrous glass mat impregnated with a resin binder to form a load-supporting filler, a plurality of ceramic tile panels fastened against each face of said filler to form a ceramic tile layer thereon, spaced integral lugs projecting from the inner surfaces of said tile panels to penetrate below the surfaces of said filler the entire length of the lugv to interlock therewith, and a bonding agent between each of said tile layers and the faces of said filler to bond the entire inner surfaces of said tile panels and all surfaces of the lugs projecting therefrom to said filler.

2. A wall structure comprising a fibrous glass mat impregnated with a resin binder to form a load-supporting filler, a plurality of ceramic tile panels fastened against each face of said filler to form a ceramic tile layer thereon, spaced integral lugs projecting from the inner surfaces of said tile panels to penetrate below the surfaces of said filler the entire length of the lug to interlock therewith, a bonding agent between each of said tile layers and the faces of said filler to bond the entire inner surfaces of said tile panels and all surfaces of the lugs projecting therefrom to said filler, and a tile facing bonded to the exposed edges of said filler.

3. A wall structure comprising a fibrous glass mat impregnated with a resin binder to form a load-supporting filler, a plurality of ceramic tile panels fastened against each face of said filler to form a ceramic tile layer thereon, spaced integral lugs projecting from the inner surfaces of said tile panels to penetrate below the surfaces of said filler the entire length of the lug to interlock therewith, a bonding agent between each of said tile layers and the faces of said filler to bond the entire inner surfaces of said tile panels and all surfaces of the lugs projecting therefrom to said filler, securing means within said filler adjacent a vertical edge and along the top edge thereof to secure the wall structure to a wall surface, and locating means within said filler along the bottom edge thereof to engage a floor surface to position said wall structure.

4. A wall structure for attachment to cooperating wall and floor surfaces with said wall structure comprising a fibrous glass mat impregnated with a resin binder to form a load-supporting filler, a plurality of ceramic tile panels fastened against each face of said filler to form a ceramic tile layer thereon, spaced integral lugs projecting from the inner surfaces of said tile panels to penetrate below the surfaces of said filler the entire length of the lug to interlock therewith, a bonding agent between each of said tile layers and the faces of said filler to bond the entire inner surfaces of said tile panels and all surfaces of the lugs projecting therefrom to said filler, and means on the bottom and vertical edges of said filler to fasten said wall structure to said cooperating wall and floor surfaces.

References Cited in the file of this patent UNITED STATES PATENTS 364,242 Frost June 7, 1887 594,749 Mitchell Nov. 30, 1897 1,930,951 Dotson Oct. 17, 1933 2,039,536 Johnson May 5, 1936 2,163,446 Heckman June 20, 1939 2,232,762 Batcheller Feb. 25, 1941 2,268,251 Haux Dec. 30, 1941 2,292,085 Powell Aug. 4, 1942 2,328,051 Bull Aug. 31, 1943 2,404,904 Collins July 30, 1946 2,725,271 Cunningham Nov. 29, 1955 2,760,881 Toulmin Aug. 28, 1956 FOREIGN FATENTS 461,314 Great Britain Feb. 8, 1937 664,199 Great Britain Jan. 2, 1952 832,669 Germany Feb. 28, 1952 

